Step 1: Determine Your Shuttlecock's Dimensions
For a complete overview of badminton brand OEM from shuttlecock production to custom tube packaging, read our Complete Badminton Brand OEM Guide.
The inner diameter of the tube must accommodate the widest point of the shuttlecock — typically the feather skirt, which flares to approximately 36–40mm on standard feather shuttlecocks. Adding 2–3mm clearance for easy insertion and removal, the standard inner diameters are: 40mm (nylon/synthetic shuttlecocks with narrow bases), 42mm (standard feather shuttlecocks — the global standard and most common), 43mm (premium feather shuttlecocks with wider bases, common in Japanese and Korean markets).
Measure your shuttlecock before ordering. Request a sample tube and test-fit your shuttlecock. A tube that's too tight causes shuttlecock deformation; too loose causes rattling and potential damage during transport.
Step 2: Choose Tube Length Based on Shuttlecock Count
Standard shuttlecock tube lengths: 6-pack tube (approximately 190–200mm), 12-pack tube (approximately 340–355mm), 15-pack tube (approximately 420–440mm). The exact length depends on shuttlecock height (typically 70–75mm for feather shuttlecocks) and the required stacking clearance between shuttlecocks.
Step 3: Select Tube Material and Wall Construction
Paper tubes with 3–5 plies (total wall thickness 1.8–2.5mm) provide adequate crush protection for most retail and distribution scenarios. Plastic tubes (HDPE/PP) are more impact-resistant but are not recyclable in most markets and are being phased out by brands responding to plastic reduction mandates. Paper is the future-proof choice for all markets.
Step 4: Cap Type Decision
Cap options: (1) friction-fit PE cap — most common, reliable, low cost, available in stock colors, can be custom-matched to Pantone; (2) screw-top cap — threaded fit, more secure, preferred for premium brands, adds $0.03–0.05/unit; (3) paper cap — fully recyclable, friction fit, limited moisture resistance, suitable for indoor retail environments. The cap is the part consumers interact with most — specify a cap that feels quality.
Step 5: Print Method and Branding
Offset printing (up to 8 colors) is the standard for shuttlecock tubes above 5,000 units. Screen printing (2–4 colors) for smaller orders. Full-bleed designs covering the entire tube surface create premium visual impact but require precise print registration. A bordered design with a 3–5mm margin is more forgiving of minor registration drift and is recommended for first-time orders.
For shuttlecock tube samples and specifications, email support@kuzopacking.com or WhatsApp +86 153-0553-6396.